Method for space dyeing yarns

ABSTRACT

A METHOD AND APPARATUS FOR THE HIGH VOLUME PRODUCTION OF SPACE DYED YARNS WHEREIN A LARGE NUMBER OF YARN STRANDS ARE INITIALLY COLLECTED INTO A UNITARY YARN ROPE. A PLURALITY OF SUCH ROPES ARE CONVEYED ALONG A SUBSTANTIALLY HORIZONTAL PATH OF TRAVEL, AND DIFFERING DYES ARE APPLIED TO SEQUENTIAL PORTIONS OF THE ROPES WHILE THEY ARE SO CONVEYED. IN THE ILLUSTRATED EMBODIMENT, THE DYES ARE APPLIED BY AN ARRANGEMENT WHICH INCLUDES A PLURALITY FO LATERALLY ALIGNED DYE APPLICATOR ROLLERS POSITIONED IMMEDIATELY BELOW THE PATH OF TRAVEL, AND A PRINTING ROLLER IS CARRIED ABOVE EACH APPLICAOTR ROLLER AND IS ADAPTED TO BE TRANSLATED BETWEEN A LOWERED POSITION TO DEPRESS THE YARN ROPES INTO OPERATIVE CONTACT WITH THE ASSOCIATED APPLICATOR ROLLER, AND A RAISED POSITION REMOVED FROM THE YARN ROPES. MOVEMENT OF EACH PRINTING ROLLER IS CONTROLLED ACCORDING TO A PREDETERMINED PROGRAMN SUCH SUCH THAT SEQUENTIAL PORTIONS OF THE YARN ROPES ARE BROUGHT INTO OPERRATIVE CONTACT WITH DIFFERNT APPLICATOR ROLLERS. SUBSEQUENT TO THE APPLICATION OF THE DYE, THE YARN ROPES MAY BE PASSED THROUGH A SUITABLE FIXATION DEVICE, AND THEN SEPARATED INTO THE COMPONENT YARN STRANDS BY A SUITABLE COMB OR THE LIKE AND WOUND EITHER ONTO INDIVIDUAL SPOOLS IN A QUILLER OR DIRECTLY ONTO A SECTION BEAM.

Sept. 19, 1972 H. L. MERCER 3,692,466

METHOD FOR SPACE DYEING YARNS Filed Oct. 23, 1970 2 Sheets-Sheet 1 5 42 A0 0 O 0 (5 Y',/ R

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ATTORNEYS Sept. 19, 1972 H. MERCER 3,692,456

METHOD FOR SPACE DYEING YARNS Filed Oct. 23, 1970 2 Sheets-Sheet 2 SEC'HONAL.

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HARRY L. MERGE-B wwfwmzwm ATTORNEYS United States Patent OE ice US. Cl. 8-1512 6 Claims ABSTRACT OF THE DISCLOSURE A method and apparatus for the high volume production of space dyed yarns wherein a large number of yarn strands are initially collected into a unitary yarn rope. A plurality of such ropes are conveyed along a substantially horizontal path of travel, and differing dyes are applied to sequential portions of the ropes while they are so conveyed. In the illustrated embodiment, the dyes are applied by an arrangement which includes a plurality of laterally aligned dye applicator rollers positioned immedi ately below the path of travel, and a printing roller is carried above each applicator roller and is adapted to be translated between a lowered position to depress the yarn ropes into operative contact with the associated applicator roller, and a raised position removed from the yarn ropes. Movement of each printing roller is controlled according to a predetermined program such that sequential portions of the yarn ropes are brought into operative contact with different applicator rollers. Subsequent to the application of the dye, the yarn ropes may be passed through a suitable fixation device, and then separated into the component yarn strands by a suitable comb or the like and wound either onto individual spools in a quiller or directly onto a section beam.

The present invention relates to a process and appara tus for the space dyeing or printing of yarn strands. More particularly, the invention relates to a continuous process for producing multi-colored yarn which is reproducible as to shade and pattern.

It has been proposed to produce space dyed yarn by a continuous process wherein a number of parallel yarn strands are fed between several pairs of dye application rollers, with each pair adapted to apply a different color to sequential portions of the strands. A control mechanism is provided to selectively operate the dye application rollers and typically comprises a rotatable endless band corresponding to the length of the recurring dye pattern and having raised cams at predetermined points along the periphery thereof. These cams cooperate with stationary followers to control the switches for actuating the different dye application rollers in accordance with a preestablished pattern.

The above process possesses several disadvantages, however, which have limited its general utility in the industry. In particular, the yarn strands are often relatively fragile and are subject to breakage when drawn through the machine. Also, since individual yarn strands are conveyed through the dyeing apparatus, the volume of yarn capable of being dyed is relatively small. Still further, there are significant synchronization problems resulting from difliculties in initially establishing the closure point of the cam follower switch on the control mechanism, and also from occasional slippage between the yarn strands and yarn transfer mechanism.

It is accordingly an object of the present invention to provide an economical process for space dyeing a yarn strand and which overcomes the disadvantages of the presently known processes.

It is another object of the present invention to provide a process for space dyeing a large number of fine yarn strands while the same are maintained in a unitary yarn 3,592,466 Patented Sept. 19, 1972 rope to thereby reduce the tension applied to the individual yarn strands and to permit high volume production.

It is a further object of the present invention to provide an arrangement which permits the yarn strands being dyed to provide the power for the printing apparatus and also the patterning device, such that the printing apparatus and patterning device may be synchonized with the linear rate of travel of the yarn strands through the apparatus.

It is a further object of this invention to provide a system for space dyeing yarn strands wherein the amount of yarn required for a complete loom warp can be dyed to the same shade and pattern from the same dye baths and at the same time to thereby effectively eliminate shade variation among the yarn strands.

It is still another object of this invention to provide a space dyeing technique wherein a number of yarn strands of differing yarn counts can be dyed at the same time to produce differing yarn capable of producing matching end products, such as matching pants and shirts.

These and other objects and advantages of the present invention are achieved in the embodiment illustrated herein by the provision of a process for dyeing a plurality of yarn strands wherein a large number of yarn strands are initially collected into a yarn rope. A plurality of such yarn ropes are conveyed along a substantially horizontal path of travel while maintained in spaced generally parallel relationship to each other, and differing dyes are applied to sequential portions of the ropes while they are conveyed along the path of travel. Subsequent to the dyeing operation, each yarn rope is separated into its component yarn strands for further conventional processing.

Some of the objects and advantages of the invention having been stated, other will appear as the description proceeds, when taken in connection with the accompanying drawings, in which FIG. 1 is a side elevational view of .a dyeing apparatus adapted for use with the present invention;

2 is a top plan view of the apparatus shown in FIG. 3 is a schematic representation similar to FIG. 1 and illustrating the manner for bringing the yarn ropes into contact with one of the applicator rollers;

FIG. 4 is a schematic representation of the control system for the individual printing rollers;

FIG. 5 is a schematic representation of a yarn rope formed according to the present invention; and

FIG. 6 is a flow diagram indicating the steps involved in dyeing a single yarn rope.

Referring more specifically to the drawings, a dyeing apparatus adapted for use with the present invention is illustrated generally at 10. The apparatus comprises a boxlike rectangular supporting framework 12 including a number of vertically extending struts 14 mounting five horizontally aligned dye applicator rollers 16, 17, 18, 19 and 20. The applicator rollers are each rotatably supported by a control shaft (not numbered) defining parallel axes, and each shaft carries a drive sprocket 22, 23, 24, 25 and 26 at one end. Five dye pans 28, 29, 30, 31, and 32 are carried by the framework such that each pan is in cooperating position with a corresponding applicator roller in the conventional manner.

The front end of the apparatus (right end as seen in the drawings) mounts a drive roller 34 which is rotatably supported by a central shaft (not numbered) defining a central axis extending parallel to the axes of the applicator rollers. The periphery of the roller 34 defines a cylindrical surface 35, and the center shaft carries a drive sprocket 36 at one end. As will be seen in FIGS. 1 and 3, the drive roller 34 is mounted at an elevation slightly above the applicator rollers 16-20 such that the uppermost portion of the surface lies above the uppermost portion of the applicator rollers. The front end of the apparatus further mounts two rotatable tension rollers 37 and 38 for guiding the yarn ropes about the cylindrical surface 35 in a manner hereinafter further described.

Five printing rollers 40, 41, 42, 43 and 44 are carried by the framework '12 adjacent and above the applicator rollers, with each printing roller being selectively translatable between a lowered position and a raised position. The apparatus for controlling this translation is illustrated schematically in FIG. 4 with regard to printing roller 46, and it will be understood that the remaining printing rollers are similarly controlled. In particular, roller is supported at each of its ends by vertical rods 48. The upper ends of the rods are secured to pistons which are translatably carried in piston chamber 52. The portions of the chambers below the pistons are in communication with the pnuematic line 54, and the portions above the pistons are in communication with the pneumatic line 56. The lines 54 and 56 are selectively connected across the four way valve 58 to a suitable pressure source 59 such that when the line 54 is connected to the source the pistons and roller 40 are raised, and when the line 56 is connected to the source the pistons and roller are lowered.

The control means for selectively operating the valve 58 to thereby translate each of the printing rollers between its lowered and raised positions according to a predetermined sequence includes a control drum 60 rotatably mounted at the front end of the apparatus 10. The drum defines a peripheral cylindrical surface 62 having provision for attaching a number of magnetic contacts 64 thereon. Typically, the drum is of lightweight tubular plastic construction, and the contacts are secured to the surface 62 by any convenient means, such as by use of an adhesive. For the reasons to become apparent, the drum 60 is removably mounted on shaft 65 such that drums of various sizes or configurations may be selectively mounted thereon. The shaft 65 in turn carries a sprocket 66 which is adapted to rotate the same. In this regard, it will be noted from FIGS. 1 and 2 that the sprocket 36 of the drive roller 34 is connected by chain 67 to the sprocket 66 of shaft 65, and that similar chains 68 interconnect the sprocket 36 with the sprockets 22-26 of the applicator rollers. Thus rotation of the drive roller 34 will cause the rotation of the applicator rollers 16-20 and the control drum 60.

A total of ten magnetic reed switches 69 are mounted immediately above and transversely across the cylindrical surface 62 of the control drum 60, with a pair of the reed switches operatively controlling each one of the printing rollers. A representative pair is shown in FIG. 4, wherein a first switch 70 is positioned to control the solenoid 7d of the valve 58 and a second switch 72 is positioned to control the solenoid 73. Thus upon rotation of the drum 60, one of the contacts 64 will, at a preselected time, be brought into the proximity of the first switch 70 to actuate solenoid 71 to thereby shift the valve central control rod toward the left. This action connects line 56 to the air source 59 while exhausting line 54, and thereby depresses the pistons 50 and printing roller 40. At a subsequent preselected time, a second contact 64 closes the second switch 72 to actuate solenoid 73 and thereby raise the roller 40 in a manner which will be apparent. In order to accurately control the closure of the various reed switches, they may be adjustably mounted for individual movement to the framework 12 of the apparatus as schematically shown in FIG. 4.

In describing the operation of the present invention, a plurality of yarn strands are drawn from a conventional creel and collected into a yarn rope R by a ball warper 82 or the like. Typically, each rope will comprise from about to 2000 single yarn strands, and the individual strands will be positioned substantially parallel and untwisted relative to each other as indicated in FIG. 5. A

number (typically 6-9) of the yarn ropes formed in the above manner are then conveyed through the dyeing apparatus 10. From the above, it will be apparent that the process of forming the individual strands into a rope and then conveying the same into the dyeing apparatus may be discontinuous. Thus balls of yarn ropes consisting of different yarn counts or compositions can be separately prepared and then simultaneously passed through the apparatus 10 such that the differing yarns will have identical dye patterns.

In the dyeing apparatus 10, the yarn ropes R are maintained in spaced generally parallel relationship to each other as best seen in FIG. 2 and are first directed about the tension rollers 37 and 38, then about a substantial portion of the circumference of the drive roller 34 to frictionally contact the same, and finally along a horizontal path of travel extending immediately above the uppermost portions of the applicator rollers 16-20 and immediately below the printing rollers 40-44. As the yarn ropes pass through the apparatus 10, the majority of the printing rollers will be retained in the raised position such that there will be no contact between the ropes and applicator rollers. However, when a contact 64 on the control drum 60 closes a first reed switch such as switch 70, the solenoid '71 will actuate valve '58 to direct the air supply into line 56 and thereby depress the printing roller. When the roller reaches its lower position, the yarn ropes will be depressed into operative contact with the roller to thereby coat the yarn rope with a layer of dye from the associated dye pan, note the position of roller 40' shown in dashed lines in FIG. 3.

After leaving the apparatus 10, the ropes normally are passed through a fixation device or drier 84 of conventional design. The fixation device serves a further function in that it preferably incorporates the means for conveying the yarn ropes through the apparatus 10. Such conveying means typically comprises a series of drive rollers similar to those conventionally used to pull cloth through a dyeing or other processing apparatus. The drawing or pulling of the yarn ropes through the apparatus 10 in this manner causes the rotation of the drive roller 34, which in turn acts through the above described sprocket and drive chain arrangement to rotate the applicator rollers 16-20 as well as the control drum 68. In order to increase the rotational speed of the rollers 16-20, the sprocket 36 on the drive roller 34 may have an increased diameter in relation to the sprockets 22-26 of the applicator rollers such that the latter will rotate at a multiple of the speed of the drive roller. By this arrangement, there will be relative movement between the depressed yarn ropes and contacted applicator rollers to thereby increase the amount of dye applied to the yarn ropes. It will also be observed that by conveying the yarn ropes through the apparatus 10 in the manner indicated, the above noted problems of synchronization of the dye application are eliminated. In this regard, the control drum 60 is synchronized with the linear rate of travel of the yarn ropes and will not be effected by any slippage of the yarn in the conveying means. Also, the exact closure time of the various reed switches can be easily adjusted to compensate for any synchronization problems by either changing the position of the contacts 64 on the drum 60, or by adjusting the positioning of the reed switches themselves.

After passing through the fixation device 84, each rope is separated into its component yarns by a suitable comb or the like, and then either placed on individual spools in a quiller 86 or placed directly onto a section beam 88 for subsequent processing in the conventional manner.

In the drawings and specification, there has been set forth a preferred embodiment of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation.

What is claimed is:

1. A method for simultaneously dyeing a plurality of yarn strands to produce a similar dye pattern on each strand comprising the steps of collecting a plurality of yarn strands into a plurality of unitary yarn ropes,

forming each of the yarn ropes into a separate ball,

conveying the yarn ropes from their respective balls and along a substantially horizontal path of travel while maintaining the same in spaced generally parallel relationship to each other,

applying differing dyes to sequential portions of the yarn ropes while the ropes are being conveyed along the horizontal path of travel, and

separating the dyed yarn ropes into their component yarn strands.

2. The method as defined in claim 1 wherein the step of collecting a plurality of yarn strands includes maintaining the strands substantially parallel and untwisted relative to each other.

3. The method as defined in claim 2 wherein the step of applying difiering dyes includes selectively contacting sequential portions of the yarn ropes against a plurality of dye applicator rollers according to a predetermined program.

4. The method as defined in claim 3 including the further subsequent step of collecting the separated yarn strands into individual yarn packages.

5. The method as defined in claim 3 including the further subsequent step of collecting the separated yarn strands on a section beam.

6. A method for simultaneously dyeing a plurality of yarn strands to produce a similar dye pattern on each strand comprising the steps of collecting a plurality of yarn strands into a plurality of unitary yarn ropes while maintaining the strands substantially parallel and untwisted relative to each other and with each of said ropes comprising from about to 2000 yarn strands,

conveying the yarn ropes along a substantially horizontal path of travel while maintaining the same in spaced generally parallel relationship to each other,

applying differing dyes to sequential portions of yarn ropes while the ropes are being conveyed along the horizontal path of travel, and

separating the dyed yarn ropes into their component yarn strands.

References Cited UNITED STATES PATENTS 747,306 12/1903 Keefer 68-202 X 2,573,097 10/1951 Epstein 68203 3,503,232. 3/ 1970 Farrer et a1 68-203 WILLIAM I. PRICE, Primary Examiner US. Cl. X.R. 28-726 

